1971 Suzuki T500 cafe racer build....

Benjo@EKCMC

63 Rickman metisse 500, 71 suzuki t500, 66 T20
Hi
Thought it would be good to keep a thread of my build as I enjoy reading other people's project progress and it's always a great source for ideas and tips along the way.

Iam in the UK down in Kent, and some months ago came across an import non runner T500 project.... I had been in search of a two stroke project bike for some time. Very much inspired by one of the guys T500's at our local classic bike club I decided to buy this one and have a go myself. I drove to Brighton and collected the bike. I wonder what people thought on the motorway while I was driving home with this on the trailer!?
 

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Tank is in the boot. No carbs. Engine loosely assembled. No Pistons...... :/
 

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This is the one that inspired me. Anyone who is into their T500's has prob seen this. Paul's at Titan Performance. Great guys there. I hope it looks this good when it is finished!
 

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Since getting it home I began stripping it down to the frame. I wanted the race look and so cut and ground down all the unecessary brackets such as centre stand, pump holder, oil tank brackets, side cover etc... I sourced some steel tube and made the diagonal bars, then welded them in place.

The frame, swing arm and lower yoke all then went off to performance Powdercoating near Canterbury, Kent for blasting and powdercoating.

I chose a graphite grey rather than the usual black for frame colour.

Pics to follow....
 
...
 

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Before and after Powdercoating :)
 

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Stripped the engine. Needs some work to get it back running. This is prob my biggest job here...
 

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Bit of time with the vapour blaster at work and the cases look much better!
 

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Looking clean once again!
 

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Oil dam mod.... Made it out of some Ali sheet
 

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Seized old switch gear. Bit of time cleaning and greasing then a bit old wire wool to polish the top yoke
 

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Dropped the wheels off at Central wheels, Birmingham last Friday to be rebuilt using stainless spokes, and alloy flanged rims with Avon roadrunner tyres. Looking forward to getting them back!
 

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Now the fun bit starts. Bolting shiney bits back on!
 

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Nice work so far
I like how you have a vapour blaster at work

Keep it coming
 
Another one I love. I wish to keep it recognisable as a t500. I think the tank pattern is important but am undecided on colours. Part of me wants to keep it the candy lavender as that was its true identity but I in a way prefer the Orange.... Opinions welcome!
 

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Like this.....? Continuing the theme along the seat unit
 

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I love both the purple and orange metallic but would choose purple being that it was that way stock. Going to be a sweet build and I will be following the progress.
Where in Kent are you from, I am from Kent originally (Tonbridge area).
 
Thankyou. Yeh Iam on the coast near Deal. I need to think about trial fitting tank to measure and cut seat unit. So this will be one of the next jobs before paint prep
 
Hey Ben.....good to see you on DOT. Thanks for your kind words about my bike. I can't believe you used one of my pictures of it, when you took some beauties yourself !
Really looking forward to seeing yours done, I know it will look the mutts nuts !
 
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